鏡面加工方式對其加工後工件表面品質非常要求,而影響加工品質的因素包括:機台剛性、切削參數、工件材質屬性以及使用的刀具,其中又以刀具影響較大,而刀具設計中刃口的研磨精度又是影響較大的因素。 本研究是針對端銑刀以側銑削方式加工鋁合金時,其加工後工件表面會產生若干條光澤度不一的現象,稱為陰陽面,並對於刀具刃口研磨精度與圓面寬度進行分析與討論。端銑刀的刃口是由切削面與離隙面所構成,而本研究在徑向離隙工程研磨第一離隙時,補正其砂輪位置使之保留一條微量的寬度,稱為圓面寬度。本研究將不探討離隙面的製程參數,而是由圓面取代離隙面。 故影響刃口研磨精度的製程參數為:(1)切削面砂輪轉速、(2)切削面砂輪進給速度以及(3)切削面NC節距。評估研磨性能特性的指標為刃口平整度,使用全因子直接找出最佳參數組合,並進行趨勢的分析與討論。本研究將探討圓面寬度之合適尺寸,以各種尺寸的圓面寬度實際加工得到工件表面,並對於圓面寬度進行分析與討論。 實驗結果中,刃口研磨精度的分析顯示「砂輪進給速度」為影響最大的因子。經過確認實驗由最佳研磨參數組合得到的刃口平整度為1.910μm;圓面寬度要平均等寬且大約介於20μm~30μm。
Mirror finishing is a high precision machining method with regard to quality of workpiece surface after process. It affects by structure rigidity of machine center, machining parameters, material properties, and cutting tools, especially the cutting tools and its grinding accuracy for cutting edges. This thesis is aimed at when using end mill machining aluminum by side milling, the workpiece surface would bring different luster on it after machining, called dark-light line, is similar to the milling mark. Therefore this study analyzed and discussed the flatness of cutting edge and width of the round bar. The cutting edge is generated by grinding rake surface and relief surface. The cutting tools keep a trace of round bar on the relief surface, so the cutting edges become generated by grinding rake surface and round bar. Therefore the grinding parameters of cutting edge are rake grain size, rake spindle rpm, rake feed rate, and rake NC step. Chipping is the major performance index of grinding process. Using factorial experiment find the optimal parameters of grinding process, then analyze and discuss the trend. The width of round bar could be control by human, so this study discusses the suitable size of the width of round bar. Using those sizes of width of round bar to machine workpieces, and analyze the result of it. The result of grinding accuracy of cutting edges shows that the rake feed rate is the main effect factor. By applying the optimal parameters of grinding process, the accuracy of cutting edge is 1.910 micrometer. The width of round bar has to equalize width, and the value should be between 15 micrometer and 40 micrometer. Experimental results show that the proposed approach can improve the grinding accuracy for cutting edges of end mills.